Support device, chair and mattress for articles of furniture

Abstract

The utility model discloses a supporting device for furniture articles, which comprises a first layer and a second layer, the first layer comprises a first polymer foam material with first density, and the first density ranges from 30kg / m < 3 > to 60kg / m < 3 >; and a second layer disposed on the first layer, the second layer comprising a second polymeric foam material having a second density ranging from 60 kg / m3 to 90 kg / m3, where the second layer comprises a single layer of the second polymeric foam material.

Description

Technical Field

[0001] Various aspects of this utility model relate to a support device for furniture articles, a method for manufacturing the support device, and a method for assembling the support device onto furniture articles. Background Technology

[0002] The following discussion of the background is intended only to facilitate understanding of the present invention. It should be understood that this discussion is not an admission or endorsement that any material mentioned was publicly available, known, or part of common general knowledge to those skilled in the art prior to the priority date of this invention.

[0003] Traditional support devices for mattresses or chairs use multiple pieces of foam material, each with a similar thickness and shape, to provide a constant firmness, thus providing support and comfort for the user.

[0004] These multi-piece foam materials may lack structural integrity, adjustable stiffness, and support, thus failing to provide the ergonomic support required for extended periods. Consequently, users of such traditional support devices may experience discomfort, stiffness, and chronic body aches after prolonged use. Over time, the foam pieces may slip or shift, diminishing their supportive function for the user.

[0005] Furthermore, traditional support devices are prone to deformation after prolonged use due to the loads applied to the material over time and / or the repeated lying and resting movements of the support structure. Additionally, manufacturing traditional support devices, which consist of multiple pieces of foam material, can be both complex and expensive.

[0006] Therefore, an improved support device and / or a method for manufacturing the support device is needed to at least solve one of the above problems. Utility Model Content

[0007] The present invention aims to provide an improved support device for furniture items. To this end, the improved support device comprises a first polymer foam material and a second polymer foam material laminated on the first polymer foam material, wherein the density of the first polymer foam material is in the range of 30 kg / m³. 3 Up to 60kg / m 3 The density of the second polymer foam material is in the range of 60 kg / m³. 3 Up to 90kg / m 3The different densities of the two polymer foam materials provide structural integrity, uniform pressure distribution, and ergonomic support for one or more users, which can alleviate user pain and thus improve user health. Furthermore, this improved support device is durable and does not easily deform even after prolonged use. For example, despite repeated lying down movements over time, the improved support device retains its original shape and structure and is suitable for providing optimal ergonomic support for users of different weights and body types. Additionally, embodiments of this invention provide a simple, low-cost, and quick-assembly manufacturing process for this improved support device.

[0008] This improved support system is particularly suitable for use as a seat base and / or backrest in chairs (such as gaming chairs or car seats), or in mattresses.

[0009] According to a first aspect of the present invention, a support device for furniture is provided, the support device comprising: a first layer comprising a first polymer foam material having a first density in the range of 30 kg / m³. 3 Up to 60kg / m 3 The second layer, disposed on the first layer, comprises a second polymer foam material having a second density in the range of 60 kg / m³. 3 Up to 90kg / m 3 The second layer comprises a single layer of the second polymer foam material.

[0010] In various embodiments, the first polymer foam material includes a first matrix structure including a plurality of first foam pores, and the second polymer foam material includes a second matrix structure including a plurality of second foam pores, the second foam pores being different from the first foam pores, wherein the density of each of the plurality of second foam pores is greater than the density of each of the plurality of first foam pores.

[0011] In various embodiments, the second matrix structure including the plurality of second foam pores has a uniform matrix structure along at least one of the transverse plane, longitudinal plane and / or diagonal plane of the second layer.

[0012] In various embodiments, the ratio of the first density to the second density ranges from 50% to 95%, and optionally, the ratio ranges from 60% to 90%.

[0013] In various embodiments, the first polymer foam material has a first indentation force deflection (IFD) value at 40% deformation, the first indentation force deflection value ranging from 20 to 80; and wherein the second polymer foam material has a second indentation force deflection value at 40% deformation, the second indentation force deflection value ranging from 250 to 500.

[0014] In various embodiments, the first layer includes: a peripheral portion located at an end of the first layer, the peripheral portion having a peripheral thickness; and an intermediate portion extending from the peripheral portion in a direction perpendicular to a transverse axis of the first layer, the intermediate portion having an intermediate thickness greater than the peripheral thickness of the peripheral portion. In some embodiments, the peripheral thickness ranges from 0.5 cm to 10 cm, and the intermediate thickness ranges from 15 cm to 25 cm.

[0015] In various embodiments, the second layer includes a recess extending at least partially along a surface of the second layer, and the first layer includes a protrusion extending at least partially from a surface of the first layer, wherein the recess of the second layer is configured to receive the protrusion of the first layer. In some embodiments, the recess includes a first recessed segment and a second recessed segment, the first recessed segment having a first recess depth and the second recessed segment having a second recess depth greater than the first recess depth, and the protrusion includes a first protruding segment and a second protruding segment, the first protruding segment having a first protrusion height and the second protruding segment having a second protrusion height greater than the first protrusion height, wherein the first recessed segment and the second recessed segment are configured to receive the first protruding segment and the second protruding segment, respectively.

[0016] In various embodiments, an adhesive layer is disposed between the first layer and the second layer, the adhesive layer being configured to secure the first layer to the second layer, wherein the thickness of the adhesive layer ranges from 0.1 cm to 0.5 cm. In some embodiments, the adhesive layer includes an adhesive means disposed at least partially along the surface of the second layer and / or at least partially along the surface of the first layer.

[0017] In various embodiments, the first polymeric foam material comprises a memory foam polymer, and the second polymeric foam material comprises a cold-curing foam polymer.

[0018] According to a second aspect of the present invention, a chair is provided, including the support device described in the first aspect. In various embodiments, the support device may include a seat base and / or a backrest of the chair. In some embodiments, the support device may include a portion of the chair, such as the central portion of the chair backrest.

[0019] According to a third aspect of the present invention, a mattress is provided, including the support device described in the first aspect.

[0020] According to a fourth aspect of the present invention, a method for manufacturing a support device for furniture articles is provided, the method comprising: providing a first layer comprising a first polymer foam material having a first density in the range of 30 kg / m³. 3 Up to 60kg / m 3 A second layer is provided, disposed on the first layer, the second layer comprising a second polymer foam material having a second density in the range of 60 kg / m³. 3 Up to 90kg / m 3 The second layer comprises a single layer of the second polymer foam material.

[0021] In various embodiments, the first polymer foam material includes a first matrix structure including a plurality of first foam pores, and the second polymer foam material includes a second matrix structure including a plurality of second foam pores, the second foam pores being different from the first foam pores, wherein the density of each of the plurality of second foam pores is greater than the density of each of the plurality of first foam pores.

[0022] In various embodiments, providing the first layer includes providing a protrusion extending at least partially from a surface of the first layer; wherein providing the second layer includes providing a recess extending at least partially along a surface of the second layer, and wherein the recess of the second layer is configured to receive the protrusion of the first layer.

[0023] In various embodiments, providing the first layer further includes: forming a peripheral portion on another surface of the first layer, the peripheral portion being located at an end of the first layer, the peripheral portion having a peripheral thickness; and forming an intermediate portion along a direction perpendicular to a transverse axis of the first layer, the intermediate portion extending from the peripheral portion, the intermediate thickness of the intermediate portion being greater than the peripheral thickness of the peripheral portion.

[0024] In various embodiments, the method further includes: providing an adhesive layer disposed on at least one of the surfaces of the first layer and / or the second layer to secure the first layer to the second layer; wherein the thickness of the adhesive layer ranges from 0.1 cm to 0.5 cm.

[0025] In various embodiments, the second layer is manufactured according to a cold-curing foam manufacturing process.

[0026] According to a fifth aspect of the present invention, a method is provided for assembling a support device according to a first aspect onto a furniture article, the furniture article including a base frame configured to receive the support device, the method comprising: positioning a second layer of the support device on the base frame of the furniture article, the second layer including at least one opening extending into the interior of the second layer, the at least one opening being configured to receive an attachment device; and attaching the second layer of the support device to the base frame of the furniture article by securing the attachment device to the at least one opening of the second layer. Attached Figure Description

[0027] The present invention will be better understood by taking into account the non-limiting examples and accompanying drawings, and by referring to the detailed description, wherein:

[0028] Figure 1 A schematic diagram showing a perspective view of an exemplary support device 100 for furniture articles;

[0029] Figure 2 It shows Figure 1 A schematic diagram of a side view of the exemplary support device 100 shown;

[0030] Figure 3 It shows Figure 1 and Figure 2 A schematic diagram of the front view of the exemplary support device 100 shown;

[0031] Figure 4 A schematic perspective view of another exemplary support device 100 for furniture articles is shown;

[0032] Figure 5 A schematic diagram of an exemplary embodiment of a chair back 200 including a support device is shown;

[0033] Figure 6 A flowchart is shown for a method 300 for manufacturing a support device for furniture articles;

[0034] Figure 7 A flowchart of a method 400 for assembling a support device onto a furniture item is shown;

[0035] Figure 8 A schematic diagram of a method 400 for fitting a support device to an exemplary furniture article including a chair seat base is shown;

[0036] Figure 9(A) illustrates a schematic diagram of a method 400 for attaching a support device to another exemplary furniture article, including a chair back; and

[0037] Figure 9(B) shows a schematic diagram of the assembled furniture item 430 including the support device. Specific Implementation

[0039] The following detailed description refers to the accompanying drawings, which illustrate by way of example specific details and embodiments in which the present invention can be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present invention. Other embodiments may be used, and structural and logical changes may be made without departing from the scope of the present invention. The various embodiments are not necessarily mutually exclusive, as some embodiments may be combined with one or more other embodiments to form new embodiments.

[0040] Features described in the context of one embodiment are correspondingly applicable to the same or similar features in other embodiments. Features described in the context of one embodiment are correspondingly applicable to other embodiments, even if not explicitly described in those other embodiments. Furthermore, additions and / or combinations and / or substitutions described for a feature in the context of one embodiment can correspondingly be applied to the same or similar features in other embodiments.

[0041] While terms such as "first" and "second" may be used to describe various elements, these elements should in no way be limited to these terms. The terms are used only to distinguish one element from another and do not define the respective elements, such as their order and / or importance. Without departing from the scope of this specification, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element.

[0042] In the context of various embodiments, the articles “a,” “some,” and “the” used to describe a feature or element include reference to one or more of that feature or element. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0043] In the context of various embodiments, the indicated values ​​or limits of indicated ranges for the terms "density," "numerical value," "thickness," "height," and "depth" provided below may refer to the average value of these terms. For example, the indicated values ​​or limits of indicated ranges for the terms "first density," "second density," "third density," "first indentation force deflection (IFD) value," "second IFD value," "first protrusion height," "second protrusion height," "first indentation depth," "second indentation depth," "peripheral thickness," "intermediate thickness," "first thickness," and "second thickness" may refer to the average value or the average limit of the range.

[0044] Throughout this specification, the term "furniture article" as used herein can refer to an article suitable for supporting and / or providing comfort to a user. This furniture article can refer to household furniture articles, such as, but not limited to, chairs, beds, sofas, recliners, and ottomans. In various embodiments, a chair can include a gaming chair, an office chair, or a dining chair. This furniture article can also refer to automotive furniture articles, such as car seats, like driver or passenger seats, or child car seats.

[0045] Throughout this specification, the term "support device" as used herein can refer to an object designed to at least support the weight of a user and to provide comfort to a user by allowing the user to rest (e.g., sit, lean, kneel, or lie flat) on the support device. Non-limiting examples of support devices may include cushions, pads, pillows, and mattresses. In various embodiments, the support device may be part of a furniture article. For example, the support device may be part of the seat base and / or backrest of a chair. In some embodiments, the support device may be a mattress. In some embodiments, the support device may be detachably attached to a furniture article.

[0046] Throughout this specification, the term "polymer foam" as used herein can refer to a solid porous matrix structure comprising foam pores, each of which may have an open-cell or closed-cell structure. The foam pores may be made of a polymer, such as polyurethane. The structural arrangement of the foam pores within the porous structure can impart mechanical properties to polymer foam materials such as density, hardness, and viscoelasticity.

[0047] Figure 1 A schematic perspective view of an exemplary support device 100 for furniture items is shown. Figure 2 and Figure 3 They are shown respectively Figure 1 The diagram shows a side view and a front view of the exemplary support device 100. Figure 4 A perspective view of another exemplary support device 100 for furniture items is shown.

[0048] refer to Figures 1 to 3The support device 100 may include the seat base of the chair. Alternatively or additionally, the support device 100 may be the backrest of the chair or a portion thereof, such as the central portion of the chair. Figure 2 As shown. In various embodiments, the chair can be a gaming chair, an office chair, or a car seat.

[0049] refer to Figures 1 to 4 The support device 100 may include a first layer 110, the first layer 110 comprising a first polymer foam material having a first density in the range of 30 kg / m³. 3 Up to 60kg / m 3 In various embodiments, when the support device 100 is as follows... Figures 1 to 3 When the seat base is included, the first density can optionally be in the range of 50 kg / m³. 3 Up to 60kg / m 3 And optionally 57.5 kg / m 3 In various other embodiments, when the support device 100 is as follows... Figure 4 When the center portion of the backrest is included, the first density can optionally be in the range of 35 kg / m³. 3 Up to 45kg / m 3 And optionally 40kg / m 3 .

[0050] The first layer 110, comprising a first polymer foam material, has a first indentation force deflection (IFD) value at 40% deformation, the first indentation force deflection value ranging from 20 to 80. In some embodiments, when the support device 100 serves as a seat base (see...), Figures 1 to 3 When the first IFD value under 40% deformation is in the range of 30 to 40, optionally 35.5. In some other embodiments, when the support device 100 serves as the central portion of the backrest (see...), Figure 4 When the deformation is 40%, the range of the first IFD value can be 45 to 55, and optionally 50.

[0051] In various embodiments, the first layer 110, comprising a first polymeric foam material, includes a first matrix structure comprising a plurality of first foam pores. The first foam pores may have an open-cell structure. The first matrix structure may include loosely stacked first foam pores, each first foam pore having an internal chamber (i.e., an open cell) filled with air. Therefore, the first matrix structure allows airflow and provides a breathable material. The first matrix structure also allows the first layer 110 to be viscoelastic, meaning that when an applied load (e.g., the weight of a user) is removed, the first layer 110 can resist deformation and can maintain its original structure and shape. In some embodiments, the first layer 110 may include a memory foam polymer.

[0052] refer to Figures 1 to 4 The support device 100 further includes a second layer 120 disposed on the first layer 110, the second layer 120 comprising a second polymer foam material having a second density in the range of 60 kg / m³. 3 Up to 90kg / m 3 The selectable range is 60kg / m 3 Up to 70kg / m 3 And optionally 66kg / m 3 Regardless of whether the second layer 120 is used as a seat base (see...) Figures 1 to 3 ) or as the central part of the backrest (see Figure 4 The second density can be the same.

[0053] In various embodiments, the second layer 120, comprising a second polymer foam material, has a second indentation force deflection (IFD) value at 40% deformation. The second indentation force deflection (IFD) value can range from 250 to 500, optionally from 250 to 350, and optionally 280. Regardless of whether the second layer 120 is used as a seat base (see...), Figures 1 to 3 ) or as the central part of the backrest (see Figure 4 The second IFD value can be the same.

[0054] The second layer 120, comprising a second polymer foam material, includes a second matrix structure comprising a plurality of second foam pores. The second foam pores may differ from the first foam pores and may have a closed-cell structure. The second matrix structure may include closely packed second foam pores, each having a closed and compact structure. Therefore, the density of each second foam pore in the second layer 120 may be greater than the density of each first foam pore in the first layer 110, and the second matrix structure may provide a more compact and dense second polymer foam material relative to the first polymer foam material, with high elastic resilience and durability. In other words, the second layer 120 may not deform when a load (e.g., the weight of a user) is applied and the applied load is removed, and may maintain its original shape and structure during long-term use. In some embodiments, the second layer 120 may include a cold-curing foam polymer.

[0055] In various embodiments, the second layer 120 comprises a single layer of second polymer foam material (e.g., a cold-curing foam polymer) and has a uniform matrix structure along at least one of the transverse, longitudinal, and / or diagonal planes of the second layer 120. In other words, the second layer 120 may comprise only a single layer (e.g., a single, discontinuous) of second polymer foam material, and unlike conventional support devices, the second layer 120 may not include multi-layered foam blocks stacked together, where multi-layered foam blocks in conventional support devices lack structural integrity and ergonomic support, and deform with prolonged use. In this respect, using a single (e.g., a single layer) of second polymer foam material throughout the second layer 120 provides uniform consistency for a uniform pressure distribution, thereby providing structural integrity and ergonomic support for one or more users, particularly because the second layer 120 does not include multiple blocks of foam material that could slide or move against each other and impair the support function of the conventional support device.

[0056] In various embodiments, the ratio of the first density of the first polymer foam material of the first layer 110 to the second density of the second polymer foam material of the second layer 120 can range from 50% to 95%, depending on the component of the furniture article to which the support device 100 is applied. In some embodiments, when the support device 100 serves as a seat base (see...), Figures 1 to 3 When the first density is used as the second density, the ratio of the first density to the second density can optionally range from 85% to 90%. In some other embodiments, when the support device 100 serves as the central portion of the backrest (see...), Figure 4 When the ratio of the first density to the second density is ), the ratio can optionally range from 55% to 60%.

[0057] In various embodiments, the first layer 110 (e.g., a memory foam polymer) can have different density ranges and IFD value ranges depending on how the support device 100 is used on the chair, while the second layer 120 (e.g., a cold-curing foam polymer) can have a constant density range and IFD value range regardless of how the support device 100 is used on the chair. For example, when the first layer 110 is used as a seat base (see...) Figures 1 to 3 The first layer 110 can have a higher density and a lower IFD value, while when the first layer 110 is used as the center part of the backrest (see...). Figure 4 The first layer 110 can have a lower density but a higher IFD value. However, when the second layer 120 serves as the central portion of the seat base or backrest, it can have a constant range of density and IFD value. Therefore, the second layer 110 can provide a robust base that does not deform under applied load, while the first layer 110 can provide a viscoelastic layer to enhance user comfort. Correspondingly, when the support device 100 serves as the seat base (see...), Figures 1 to 3 ), providing optimal ergonomic support for extended comfort; and when the support device 100 serves as the central portion of the backrest (see... Figure 4 Despite repeated lying down movements, the backrest can still resist deformation.

[0058] refer to Figure 2 The first layer 110 (e.g., a memory foam polymer) may also include a protrusion 116 extending at least partially from the surface of the first layer 110. The protrusion 116 may extend from a surface configured to be disposed on the second layer 120. The protrusion 116 may include a first protruding segment 118 disposed at one end of the protrusion 116 and a second protruding segment 119 disposed at the other end (e.g., the opposite end) of the protrusion 116, and in various embodiments, the first protruding segment 118 may extend and lead to the second protruding segment 119. It is contemplated that the protrusion 116 may extend completely along the surface of the first layer 110.

[0059] In various embodiments, the first protrusion 118 may have a first protrusion height h1, while the second protrusion 119 may have a second protrusion height h2 greater than the first protrusion height h1. In some embodiments, the first protrusion height h1 may range from 5 mm to 3 cm, optionally from 1 cm to 3 cm, and the second protrusion height h2 may range from 4 cm to 6 cm.

[0060] The second layer 120 (e.g., a cold-curing foam polymer) may include a recess 122 extending at least partially along the surface of the second layer 120. The recess 122 may be disposed on a surface configured to be stacked on the first layer 110 and may be configured to receive a protrusion 116 of the first layer 110. The recess 122 may include a first recessed segment 124 disposed at one end of the recess 122 and a second recessed segment 126 disposed at the other end (e.g., the opposite end) of the recess 122. For example, as... Figure 2 As shown, the first recessed segment 124 can extend to and lead to the second recessed segment 126. It is conceivable that the recess 122 can extend completely along the surface of the second layer 120.

[0061] In various embodiments, the first recessed segment 124 may have a first recess depth d1, and the second recessed segment 126 may have a second recess depth d2 greater than the first recess depth d1. In some embodiments, the first recess depth d1 may range from 5 mm to 3 cm, and the second recess depth d2 may range from 4 cm to 6 cm, thereby corresponding to the first protrusion height h1 and the second protrusion height h2 of the protrusion 116, respectively. Therefore, the first recessed segment 124 and the second recessed segment 126 may be configured to receive the first protrusion segment 118 and the second protrusion segment 119, respectively.

[0062] The protrusion 116 of the first layer 110 and the corresponding recess 122 of the second layer 120 configured to receive the protrusion 116 simplify the manufacturing assembly and process of the support device 100 by ensuring that the first layer 110, which has a lower IFD value (i.e., softer), can be easily fitted and assembled onto the second layer 120, which has a higher IFD value (i.e., harder). Furthermore, when the support device 100 serves as the central portion of the backrest (see...), Figure 4 The fit between the protrusion 116 and the recess 122 allows the support device 100 to maintain its original shape and structure even during repeated reclining movements of the backrest. Although Figures 1 to 4 The fit between the recess 122 and the protrusion 116 of the support device 100 is shown, but it is conceivable that the support device 100 may include other fit structures to facilitate the stacking of the first layer 110 on the second layer 120, thereby simplifying the assembly and manufacturing process.

[0063] In various embodiments, the support device 100 further includes an adhesive layer 130 disposed between the first layer 110 and the second layer 120, the adhesive layer 130 being configured to secure the first layer 110 to the second layer 120. In various embodiments, the adhesive layer 130 may include adhesive means disposed at least partially or completely along the surface of the second layer 120, and / or adhesive means disposed at least partially or completely along the surface of the first layer 110. In some embodiments, the adhesive means may be disposed partially or completely on both surfaces of the first layer 110 and the second layer 120. For example, the adhesive means may be disposed on a protrusion 116, such as a first protruding segment 118 and / or a second protruding segment 119 of the first layer 110, and / or on a recess 122, such as a first recessed segment 124 and a second recessed segment 126 of the second layer 120. Non-limiting examples of adhesive means include adhesive and / or one or more Velcro straps. It is contemplated that the adhesive means may include any suitable means for securing the first layer 110 and the second layer 120 together.

[0064] In various embodiments, the thickness of the adhesive layer 130 can range from 0.1 cm to 0.5 cm, optionally from 0.1 cm to 0.3 cm. In some embodiments, the thickness of the adhesive layer 130 can be uniform to avoid causing discomfort to the user when using the support device 100.

[0065] like Figures 1 to 3 As shown, the support device 100 can serve as a seat base. In this case, the support device 100 may also include outwardly extending edges 140 and 150 disposed on opposite sides of the support device 100. In various embodiments, the first layer 110 may include first outwardly extending edges 142 and 152 disposed on the second outwardly extending edges 144 and 154 of the second layer 120.

[0066] In various embodiments, the first layer 110 may further include a peripheral portion 112 located at an end of the first layer 110 and an intermediate portion 114 extending from the peripheral portion 112 in a direction perpendicular to the transverse axis of the first layer 110. For example, the intermediate portion 114 may extend upward away from the peripheral portion 112. In various embodiments, the peripheral portion 112 may have a peripheral thickness t1, and the intermediate portion 114 may have an intermediate thickness t2 greater than the peripheral thickness t1 (see [link to relevant documentation]). Figure 2 In some embodiments, the peripheral thickness t1 ranges from 0.5 cm to 10 cm, optionally from 5 cm to 10 cm; the intermediate thickness t2 ranges from 15 cm to 25 cm, optionally from 18 cm to 22 cm. The different thicknesses and gradients between the peripheral portion 112 and the intermediate portion 114 of the support device 100 form a "pebble-shaped" seat base, providing optimal ergonomic support for the natural movement of the spine by offering a larger contact area and a more uniform pressure distribution. Furthermore, the flared edges 140, 150 can provide more space to accommodate various user postures. It is also conceivable that, when the support device 100 is used as a seat base, the thickness of the first layer 110 and / or the second layer 120 and their respective portions can be varied to improve the ergonomic performance of the support device 100.

[0067] In various embodiments, the second layer 120 may include a first portion 121 located at one end of the second layer 120 and having a first thickness, and a second portion 123 located at the opposite end of the second layer 120 and having a second thickness (see [link to previous embodiment]). Figure 1 In some embodiments, the first thickness of the first portion 121 can range from 1 cm to 2.5 cm; the second thickness of the second portion 123 can range from 0.5 cm to 5 cm.

[0068] In various other embodiments, reference is made to Figure 4 The support device 100 can serve as the central part of the backrest. The second layer 120 includes a first portion 121 located at one end of the second layer 120 and having a first thickness, and a second portion 123 located at the opposite end of the second layer 120 and having a second thickness. In some other embodiments, the first thickness of the first portion 121 can range from 0.5 cm to 2 cm; while the second thickness of the second portion 123 can range from 1 cm to 2.5 cm.

[0069] Figure 5 A schematic diagram of an exemplary embodiment of a chair backrest 200 including a support device is shown. The support device may refer to... Figures 1 to 4 The repeated description of the support device 100 discussed will be omitted.

[0070] The backrest 200 may also include a contour layer 210 disposed near the side of the support device 100. The contour layer 210 may include a headrest 212 disposed near one side of the support device 100 and inclined side wings 214, 216 located on opposite sides of the support device 100.

[0071] In various embodiments, the contour layer 210 may include a third polymer foam material having a third density in the range of 60 kg / m³. 3 Up to 90kg / m 3 The selectable range is 60kg / m 3 Up to 70kg / m 3 And optionally 66kg / m 3 However, the IFD value of the third polymer foam material at 40% deformation can range from 250 to 500, optionally from 400 to 500, and optionally 423. In one embodiment, the third polymer foam material may comprise a cold-curing foam polymer. In other words, the contour layer 210 can be similar to the second layer 120 because the third density of the third polymer foam material can be the same as the second density of the second layer 120, but the contour layer 210 can have a higher IFD value, i.e., it is stiffer, compared to the second layer 120. Therefore, during repeated reclining movements of the backrest 200, the contour layer 120 can provide additional support for the support device 100, and the support device 100 can maintain its original shape and structure.

[0072] Although the support device 100 is described with reference to the first layer 110 and the second layer 120, it is also contemplated that the support device 100 may further include one or more additional layers disposed on the first layer 110 and / or the second layer 120 and / or between the first layer 100 and the second layer 120. Furthermore, it is contemplated that the first polymer foam material, the second polymer foam material, and / or the third polymer foam material may include perforations to optimize pressure distribution.

[0073] According to another aspect of the present invention, a chair is provided, comprising a reference... Figures 1 to 5 The support device 100 under discussion. In various embodiments, the support device 100 may serve as a seat base (see...). Figures 1 to 3 ), and / or as part of, for example, the center portion of the backrest (see Figure 4 and Figure 5 ).

[0074] According to another aspect of the present invention, a mattress is also provided, which includes a reference... Figures 1 to 5The support device 100 under discussion. In various embodiments, the support device 100 may be located at the bottom of the mattress, and the mattress may further include one or more additional layers disposed on the first layer 110. It is contemplated that the one or more additional layers may include a viscoelastic material, such as a memory foam polymer.

[0075] Figure 6 A flowchart is shown of a method 300 for manufacturing a support device for furniture articles according to another aspect of the present invention. The support device may refer to... (referring to...) Figures 1 to 5 The supporting device 100 discussed herein will be omitted if repeated discussion is required.

[0076] Method 300 includes: providing a first layer comprising a first polymeric foam material having a first density in the range of 30 kg / m³. 3 Up to 60kg / m 3 (Step 302); Provide a second layer disposed on the first layer, the second layer comprising a second polymer foam material having a second density in the range of 60 kg / m³. 3 Up to 90kg / m 3 The second layer comprises a single layer of second polymer foam material (step 306). Method 300 may further include: providing an adhesive layer disposed on at least one of the surfaces of the first layer and / or the second layer to secure the first layer to the second layer (step 304).

[0077] In various embodiments, in step 302, when the seat base includes a first layer, the first density may optionally be in the range of 50 kg / m³. 3 Up to 60kg / m 3 And optionally 57.5 kg / m 3 In various other embodiments, when the first layer serves as the central portion of the backrest, the first density may optionally range from 35 kg / m³. 3 Up to 45kg / m 3 And optionally 40kg / m 3 .

[0078] In various embodiments, in step 302, the first polymer foam material has a first IFD value at 40% deformation, the first IFD value ranging from 20 to 80. When the first layer serves as a seat base, the first IFD value at 40% deformation can range from 30 to 40, optionally 35.5. When the first layer serves as the center portion of the backrest, the first IFD value at 40% deformation can range from 45 to 55, optionally 50.

[0079] In various embodiments, the first polymeric foam material may be a memory foam polymer. The first layer comprising the first polymeric foam material may be manufactured according to a memory foam manufacturing process, which may include the step of molding the first polymeric foam material at a temperature range of 20°C to 35°C (optionally 25°C to 30°C).

[0080] In various embodiments, providing the first layer in step 302 may further include providing a protrusion that extends at least partially from the surface of the first layer. In some embodiments, the protrusion may include a first protrusion segment having a first protrusion height and a second protrusion segment having a height greater than the first protrusion height.

[0081] In various embodiments, providing the first layer in step 302 may further include: forming a peripheral portion on another surface of the first layer, the peripheral portion being located at an end of the first layer and having a peripheral thickness; and forming an intermediate portion extending from the peripheral portion along a direction perpendicular to the transverse axis of the first layer, the intermediate portion having an intermediate thickness greater than the peripheral thickness of the peripheral portion.

[0082] In various embodiments of method 300, a first polymer foam material has a first matrix structure including a plurality of first foam pores, and a second polymer foam material has a second matrix structure including a plurality of second foam pores, the second foam pores being different from the first foam pores. The density of each of the plurality of second foam pores may be greater than the density of each of the plurality of first foam pores.

[0083] In various embodiments, in step 306, providing a second layer comprising a single layer of second polymer foam material may include providing a single layer (e.g., a single and discontinuous) of second polymer foam material having a second matrix structure comprising a plurality of second foam pores. In some embodiments, the second foam pores may comprise a closed-cell structure. In other words, the second layer may not include multiple layers of foam blocks stacked together, but only a single layer of second polymer foam material. Therefore, the second matrix structure may also have a uniform matrix structure along at least one of the transverse plane, longitudinal plane, and / or diagonal plane of the second layer. In this way, because the second layer does not include multiple layers of foam blocks stacked together, which could slide and move against each other, thereby impairing the support function of the second layer, a second layer consisting of a single layer can provide the required structural integrity and ergonomic support for one or more users.

[0084] In various embodiments, providing the second layer in step 306 may further include: providing a second density range of 60 kg / m³. 3 Up to 90kg / m 3The second polymer foam material, optionally with a second density range of 60 kg / m³. 3 Up to 70kg / m 3 And optionally 66kg / m 3 Whether the second layer is used as the seat base or the center of the backrest, the second density can be the same.

[0085] In various embodiments, providing the second layer in step 306 may further include providing a second polymeric foam material with a second IFD value ranging from 250 to 500 at 40% deformation, optionally with a second IFD value ranging from 250 to 350, and optionally 280. The second IFD value can be the same regardless of whether the second layer is used as the center portion of the seat base or the backrest.

[0086] In various embodiments, the second polymer foam material may be a cold-curing foam polymer. The second layer comprising the second polymer foam material may be manufactured according to a cold-curing manufacturing process, which may include the step of molding the second polymer foam material at a temperature range of 20°C to 35°C (optionally 25°C to 30°C).

[0087] In various embodiments, providing the second layer in step 306 may further include providing a recess that extends at least partially along the surface of the second layer. The recess of the second layer may be configured to receive a protrusion of the first layer.

[0088] In various embodiments, providing the adhesive layer in step 304 may include providing the adhesive layer on the raised surface of the first layer and / or the recessed surface of the second layer. In some embodiments, the thickness of the adhesive layer may range from 0.1 cm to 0.5 cm, optionally from 0.1 cm to 0.3 cm.

[0089] Figure 7 A flowchart of a method 400 for assembling a support device onto a furniture article according to another aspect of the present invention is shown. Figure 8 A schematic diagram of a method 400 for attaching a support device to an exemplary furniture article including a chair seat base is shown. Figure 9(A) shows a schematic diagram of a method 400 for attaching a support device to another exemplary furniture article including a chair backrest, and Figure 9(B) shows a schematic diagram of an assembled furniture article 430 including the support device. The support device may refer to... Figures 1 to 5 The support device 100 under discussion.

[0090] refer to Figure 7 Referring to Figures 9(A) and 9(B), the furniture article may include a base 410 configured to receive the support device 100. For example, as Figure 8As shown, the base frame 410 may be sized to receive the support device 100 including the seat base; and in FIG. 9(A), the base frame 420 may be sized to receive the backrest 200 including the support device 100 (as the central portion of the backrest 200). In various embodiments, the base frame 410 may include at least one base frame opening 412 configured to receive attachment devices.

[0091] Method 400 includes: positioning a second layer of the support device on the base of a furniture article, the second layer including at least one opening extending into the interior of the second layer, the at least one opening being configured to receive an attachment device (step 402); attaching the second layer of the support device to the base of the furniture article by securing the attachment device to at least one opening of the second layer (step 404).

[0092] In various embodiments, the second layer 120 of the support device may include at least one opening 160 extending into the interior of the second layer 120. Therefore, in step 402 of method 400, positioning the second layer 120 onto the base frame 410 may include positioning, for example, aligning at least one opening 160 of the second layer 120 with at least one base frame opening 412 of the base frame 410 (see...). Figure 8 ).

[0093] In some embodiments shown in FIG9(A), a support device 100 including a central portion of the backrest can be first assembled onto the contour layer 210 of the backrest. The contour layer 210 may include at least one contour opening 222 extending through the interior of the contour layer 210 and configured to receive an attachment device. In this embodiment, in step 402 of method 400, positioning the second layer 120 onto the base frame 410 may include: (i) positioning, for example, aligning at least one opening 160 of the second layer 120 with at least one contour opening 222 of the contour layer 210; and (ii) positioning, for example, aligning at least one opening 160 of the second layer 120 and at least one contour opening 222 of the contour layer 210 with at least one base frame opening 412 of the base frame 410. It is contemplated that the attachment device may pass through the base frame opening 412 and the contour opening 222 to assemble the backrest 200 onto the base frame 410 of the furniture item.

[0094] In various embodiments, in step 404 of method 400, attaching the second layer of the support device to the base 410 of the furniture article may further include: inserting the attachment device through the base opening 412 and the opening 160 of the second layer (see...). Figure 8 In some embodiments, step 404 may further include inserting the attachment device through the base frame opening 412, the profile opening 222, and the second layer opening 160 (see FIG. 9(A)).

[0095] In various embodiments, the attachment means may include any means suitable for securing the support 100 (e.g., the second layer 120) to the base 410 of the furniture article. In some embodiments, the attachment means may include rivets, nails, or screws.

[0096] Therefore, embodiments of this invention provide an improved support device 100 with different densities between two polymer foam materials to provide structural integrity, uniform pressure distribution, and ergonomic support for one or more users. This can alleviate user pain and improve user health. The improved support device 100 is also durable and will not deform over prolonged use. For example, the improved support device 100 maintains its original shape and structure even with repeated reclining movements over time (as part of a backrest). The improved support device 100 is also suitable for users of various weights and body types. This invention also provides a method for manufacturing the improved support device 100, which is simple, inexpensive, and quick to assemble.

Claims

1. A support device for furniture, characterized in that, The support device includes: The first layer comprises a first polymer foam material having a first density, wherein the first density is in the range of 30 kg / m³. 3 Up to 60kg / m 3 ;and The second layer is disposed on the first layer, and the second layer comprises a second polymer foam material having a second density in the range of 60 kg / m³. 3 Up to 90kg / m 3 , The second layer comprises a single layer of the second polymer foam material.

2. The support device according to claim 1, characterized in that, The first polymer foam material includes a first matrix structure, and the first matrix structure includes a plurality of first foam pores. The second polymer foam material includes a second matrix structure, which comprises a plurality of second foam pores, the second foam pores being different from the first foam pores. The density of each of the plurality of second foam pores is greater than the density of each of the plurality of first foam pores.

3. The support device according to claim 2, characterized in that, The second matrix structure, including the plurality of second foam pores, has a uniform matrix structure along at least one of the transverse plane, longitudinal plane, and / or diagonal plane of the second layer.

4. The support device according to any one of claims 1 to 3, characterized in that, The ratio of the first density to the second density ranges from 50% to 95%, and optionally, the ratio ranges from 60% to 90%.

5. The support device according to any one of claims 1 to 3, characterized in that, The first polymer foam material has a first indentation force deflection (IFD) value at 40% deformation, and the first indentation force deflection value ranges from 20 to 80. and The second polymer foam material has a second indentation force deflection value under 40% deformation, and the range of the second indentation force deflection value is 250 to 500.

6. The support device according to any one of claims 1 to 3, characterized in that, The first layer includes: The peripheral portion, located at the end of the first layer, has a peripheral thickness; and The middle portion extends from the peripheral portion in a direction perpendicular to the lateral axis of the first layer, and the middle thickness of the middle portion is greater than the peripheral thickness of the peripheral portion.

7. The support device according to claim 6, characterized in that, The peripheral thickness ranges from 0.5cm to 10cm, and the intermediate thickness ranges from 15cm to 25cm.

8. The support device according to any one of claims 1 to 3, characterized in that, The second layer includes a recess extending at least partially along the surface of the second layer, and the first layer includes a protrusion extending at least partially from the surface of the first layer. The recess in the second layer is configured to receive the protrusion in the first layer.

9. The support device according to claim 8, characterized in that, The recess includes a first recessed segment and a second recessed segment. The first recessed segment has a first recessed depth, and the second recessed segment has a second recessed depth, wherein the second recessed depth is greater than the first recessed depth. The protrusion includes a first protruding segment and a second protruding segment. The first protruding segment has a first protrusion height, and the second protruding segment has a second protrusion height, wherein the second protrusion height is greater than the first protrusion height. The first recessed section and the second recessed section are configured to receive the first protruding section and the second protruding section, respectively.

10. The support device according to claim 8, characterized in that, The support device further includes an adhesive layer disposed between the first layer and the second layer, the adhesive layer being configured to secure the first layer to the second layer. The adhesive layer has a thickness ranging from 0.1 cm to 0.5 cm.

11. The support device according to claim 10, characterized in that, The adhesive layer includes an adhesive device disposed at least partially along the surface of the second layer and / or at least partially along the surface of the first layer.

12. The support device according to any one of claims 1 to 3, characterized in that, The first polymer foam material includes a memory foam polymer, and the second polymer foam material includes a cold-curing foam polymer.

13. A chair, characterized in that, Includes the support device according to any one of claims 1 to 12.

14. A mattress, characterized in that, Includes the support device according to any one of claims 1 to 12.

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